Continuously Variable Transmission (TR690) (Service Information): Other Subaru Forester SJ

OIL PUMP

TRANSMISSION CONTROL ELEMENT

TRANSMISSION GEAR RATIO

PLATE

SELECTOR POSITION

TRANSFER

REDUCTION GEAR RATIO

RECOMMENDED GEAR OIL

Lubrication oil Front differential oil capacity L (US qt, Imp qt) 1.3 - 1.5 (1.4 - 1.6, 1.1 - 1.3)

Scheme 876

Scheme 877

Tightening torque: N.m (kgf-m, ft-lb)

T1: 9 (0.9, 6.6)

T2: 16 (1.6, 11.8)

T3: 18 (1.8, 13.3)

T4: 25 (2.5, 18.4)

T5: 35 (3.6, 25.8)

T6: 41 (4.2, 30.2)

T7: 50 (5.1, 36.9)

T8: 70 (7.1, 51.6)

T9: < Ref. to INSTALLATION , Drive Plate. >

Scheme 878

Tightening torque: N.m (kgf-m, ft-lb)

T1: 8.5 (0.9, 6.3)

T2: 24 (2.4, 17.7)

Scheme 879

Tightening torque: N.m (kgf-m, ft-lb)

T1: 13 (1.3, 9.6)

T2: 16 (1.6, 11.8)

T3: 25 (2.5, 18.4)

T4: 35 (3.6, 25.8)

T5: 40 (4.1, 29.5)

Scheme 880

Tightening torque: N.m (kgf-m, ft-lb)

T1: 5 (0.5, 3.7)

T2: 9 (0.9, 6.6)

T3: 39.2 (4.0, 28.9)

T4: 50 (5.1, 36.9)

Scheme 881

Tightening torque: N.m (kgf-m, ft-lb)

T: 25 (2.5, 18.4)

Scheme 882

Scheme 883

Tightening torque: N.m (kgf-m, ft-lb)

T1: 21.5 (2.2, 15.9)

T2: 24 (2.4, 17.7)

T3: 25 (2.5, 18.4)

Scheme 884

Tightening torque: N.m (kgf-m, ft-lb)

T1: 5 (0.5, 3.7)

T2: 7 (0.7, 5.2)

T3: 25 (2.5, 18.4)

Scheme 885

Tightening torque: N.m (kgf-m, ft-lb)

T1: 21 (2.1, 15.5)

T2: 25 (2.5, 18.4)

T3: 33 (3.4, 24.3)

Scheme 886

Tightening torque: N.m (kgf-m, ft-lb)

T1: 25 (2.5, 18.4)

T2: 43 (4.4, 31.7)

T3: < Ref. to DIFFERENTIAL CASE ASSEMBLY , ASSEMBLY, Front Differential Assembly. >

T4: 70 (7.1, 51.6)

T5: 130 (13.3, 95.9)

Scheme 887

Tightening torque: N.m (kgf-m, ft-lb)

T: 25 (2.5, 18.4)

Scheme 888

Tightening torque: N.m (kgf-m, ft-lb)

T1: 5 (0.5, 3.7)

T2: 8 (0.8, 5.9)

T3: 16 (1.6, 11.8)

T4: 39 (4.0, 28.8)

Scheme 889

Tightening torque: N.m (kgf-m, ft-lb)

T: 23 (2.3, 17.0)

Scheme 890

Tightening torque: N.m (kgf-m, ft-lb)

T: 7.5 (0.8, 5.5)

Scheme 891

Tightening torque: N.m (kgf-m, ft-lb)

T1: 35 (3.6, 25.8)

T2: 40 (4.1, 29.5)

T3: 50 (5.1, 36.9)

T4: 58 (5.9, 42.8)

T5: 70 (7.1, 51.6)

CAUTION

1. Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust and dirt.
4. Do not place the oil pan with its inner side facing up until it is installed, to prevent intrusion of foreign matter into the control valve body.
5. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
6. When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do not pry apart with screwdrivers or other tools.
7. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
8. Use SUBARU genuine CVTF and recommended grease. Do not mix CVTF, grease etc. of different grades or manufacturers.
9. Be sure to tighten bolts and nuts to the specified torque.
10. Place lifts, shop jacks or rigid racks at specified locations.
11. Apply CVTF onto sliding or revolving surfaces before installation.
12. Apply CVTF onto the press-fitting surface of the part before press-fitting the part using a press.
13. Replace deformed or damaged snap rings with new parts.
14. Before installing O-rings or oil seals, apply sufficient amount of CVTF to avoid damage and deformation.
15. Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts.
16. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise.
17. Avoid damaging the mating surface of the case.
18. Before applying liquid gasket, completely remove the old liquid gasket.
19. After removing the sensors, breather hose and plugs, plug the holes to avoid foreign materials intruding as necessary.
20. During disassembly or assembly, be sure to use nylon gloves or paper towels. Do not use cloth gloves or waste cloth.

GENERAL TOOL

CONDITION CHECK

Note. When replacing CVTF, determine the condition inside the transmission body by inspecting the drained CVTF.

PROCEDURE

Note. During variator chain break-in, VDC warning light illuminate because of the difference between the vehicle speed value and G sensor value. This is not a malfunction. If the warning light illuminates, clear the VDC memory after the variator chain break-in is finished. < Ref. to CLEAR MEMORY MODE . > If the above malfunction code is detected during variator chain break-in, the system enters into fail mode, and the vehicle shows symptom such as engine speed rapid increases even if the accelerator pedal is gradually depressed.

1. Lift up the vehicle. CAUTION: Lift up the vehicle until the tire bottom is 0.3 m (0.98 ft) or more above the ground.
2. Shift the select lever to "P" or "N" range.
3. Apply the parking brake.
4. Connect the Subaru Select Monitor to data link connector.
5. Idle the engine to raise the CVTF temperature to 40 - 50°C (104 - 122°F) displayed on the Subaru Select Monitor. NOTE: When CVTF temperature does not rise easily or if you want to rise CVTF temperature faster, maintain the engine speed within 2, 000 - 2, 500 rpm at "P" or "N" range to raise the CVTF temperature.
6. With the select lever in "P" or "N" range, increase the engine speed to 3, 000 - 3, 500 rpm from the idling condition, and maintain the speed for approximately five seconds, then release the accelerator pedal.
7. Depress the accelerator pedal gradually again from idling condition to increase the engine speed to 3, 000 - 3, 500 rpm, maintain the speed for approximately five seconds, then release the accelerator pedal.
8. Release the parking brake.
9. Shift the select lever into manual mode and set to 1st.
10. Depress the accelerator pedal gradually, and increase the engine speed to 5, 300 rpm from engine idling condition. NOTE: Increase the engine speed while taking care that the engine speed does not become too high.
11. Release the accelerator pedal to fully closed position to lower the engine speed to 4, 000 rpm.
12. Depress the accelerator pedal gradually again, and increase the engine speed to 5, 300 rpm.
13. Repeat the step 11 ) and 12 ) for 40 times.
14. Release the accelerator pedal to return the engine speed to idling.
15. Shift the select lever to "P" range, and then turn the engine to OFF.

1. Shift the select lever to "P" range.
2. Connect the Subaru Select Monitor to data link connector.
3. Turn the ignition switch to ON. (For model with push button start, press the push button ignition switch twice without depressing brake pedal.)
4. Turn off all switches causing an electrical load, such as headlights, A/C, seat heater and rear defogger.
5. Select {Work Support} in the «Transmission Diagnosis» display screen of the Subaru Select Monitor.
6. Select {Maintenance mode} in the «Work Support» screen of Subaru Select Monitor.
7. Select {AWD ON/OFF switching mode} in the «Maintenance mode» screen of the Subaru Select Monitor.
8. Follow the messages displayed on the Subaru Select Monitor screen when working. Switching completes successfully if any of the following messages is displayed. When switching from AWD to FWD: {Switched to FF. To return to AWD, perform basic mode again.} When switching from FWD to AWD: {Switched to AWD. To return to FF, perform basic mode again.} NOTE: If communication error occurs during switching mode, start in the "AWD ON/OFF switching mode" again. If operation is interrupted before the successful end message is displayed, perform the {AWD ON/OFF switching mode} from the beginning until confirming the operation is successfully ended. If this mode fails to complete successfully, the cause is as follows. Select lever is not in "P" range. Engine is running. For detailed operation procedures, refer to "PC application help for Subaru Select Monitor".

GENERAL PRECAUTION

Road tests should be conducted to properly diagnose the condition of CVT.

D RANGE SHIFT FUNCTION

In intelligent mode, make sure the engine speed is 1, 100 - 1, 300 rpm while driving on the level road at 50 km/h (31 MPH) after accelerating from halting to 1/4 of accelerator opening angle. Then stop the vehicle. Check normal gear change has occurred while the vehicle speed changes from a constant speed to zero.

KICK-DOWN FUNCTION

Check if engine speed will rise by operating the accelerator opening angle to the full from a constant speed of 50 km/h (31 MPH) or more.

When in S# mode

1. Drive in "8th speed of manual mode" [90 - 100 km/h (56 - 62 MPH)], and shift down from 8th to 7th. Check if the indicator of combination meter switches "8" --> "7". At the same time, check engine braking in 7th gear.
2. Drive in "7th speed of manual mode" [80 - 90 km/h (50 - 56 MPH)], and shift down from 7th to 6th. Check if the indicator of combination meter switches "7" --> "6". At the same time, check engine braking in 6th gear.
3. Drive in "6th speed of manual mode" [70 - 80 km/h (43 - 50 MPH)], and shift down from 6th to 5th. Check if the indicator of combination meter switches "6" --> "5". At the same time, check the engine brake in 5th gear.
4. Drive in "5th speed of manual mode" [60 - 70 km/h (37 - 43 MPH)], and shift down from 5th to 4th. Check if the indicator of combination meter switches "5" --> "4". At the same time, check the engine brake in 4th gear.
5. Drive in "4th speed of manual mode" [50 - 60 km/h (31 - 37 MPH)], and shift down from 4th to 3rd. Check if the indicator of combination meter switches "4" --> "3". At the same time, check the engine brake in 3rd gear.
6. Drive in "3rd speed of manual mode" [30 - 40 km/h (19 - 25 MPH)], and shift down from 3rd to 2nd. Check if the indicator of combination meter switches "3" --> "2". At the same time, check the engine brake in 2nd gear.
7. Drive in "2nd speed of manual mode" [20 - 30 km/h (12 - 19 MPH)], and shift down from 2nd to 1st. Check if the indicator of combination meter switches "2" --> "1". At the same time, check the engine brake in 1st gear.

Other than in S# mode

1. Drive in "6th speed of manual mode" [70 - 80 km/h (43 - 50 MPH)], and shift down from 6th to 5th. Check if the indicator of combination meter switches "6" --> "5". At the same time, check the engine brake in 5th gear.
2. Drive in "5th speed of manual mode" [60 - 70 km/h (37 - 43 MPH)], and shift down from 5th to 4th. Check if the indicator of combination meter switches "5" --> "4". At the same time, check the engine brake in 4th gear.
3. Drive in "4th speed of manual mode" [50 - 60 km/h (31 - 37 MPH)], and shift down from 4th to 3rd. Check if the indicator of combination meter switches "4" --> "3". At the same time, check the engine brake in 3rd gear.
4. Drive in "3rd speed of manual mode" [40 - 50 km/h (25 - 31 MPH)], and shift down from 3rd to 2nd. Check if the indicator of combination meter switches "3" --> "2". At the same time, check the engine brake in 2nd gear.
5. Drive in "2nd speed of manual mode" [20 - 30 km/h (12 - 19 MPH)], and shift down from 2nd to 1st. Check if the indicator of combination meter switches "2" --> "1". At the same time, check the engine brake in 1st gear.

LOCK-UP FUNCTION

When the accelerator is lightly depressed while driving on a flat road in "D" range, check that rpm does not change abruptly.

OIL LEAKAGE

After the driving test, inspect for leakage of CVTF and differential gear oil from the transmission body.

PITCHING STOPPER

1. Disconnect the ground cable from battery.
2. Remove the intercooler. < Ref. to «REMOVAL»(ref-662121-S20295609002014101300000) , Intercooler. >
3. Remove the pitching stopper.

TRANSMISSION REAR CROSSMEMBER AND REAR CUSHION RUBBER

1. Disconnect the ground cable from battery.
2. Lift up the vehicle.
3. Remove the center exhaust pipe. < Ref. to «REMOVAL»(ref-662147-S02884487272014101300000) , Center Exhaust Pipe. >
4. Remove the center exhaust cover.
5. Set the transmission jack under the transmission. Make sure that the support plate of transmission jack does not touch the oil pan.
6. Remove the transmission rear crossmember.
7. Remove the rear cushion rubber.

1. Install the pitching stopper. Tightening torque: T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb) T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb)
2. Install the intercooler. < Ref. to «INSTALLATION»(ref-662121-S02050373282014101300000) , Intercooler. >
3. Connect the battery ground terminal.

1. Install the rear cushion rubber on the transmission. Tightening torque: 40 N.m (4.1 kgf-m, 29.5 ft-lb)
2. Install the transmission rear crossmember. Tightening torque: T1: 35 N.m (3.6 kgf-m, 25.8 ft-lb) T2: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
3. Remove the transmission jack.
4. Install the center exhaust cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
5. Install the center exhaust pipe. < Ref. to «INSTALLATION»(ref-662147-S36466400162014101300000) , Center Exhaust Pipe. >
6. Connect the battery ground terminal.

CHECK SWITCH UNIT

Measure the resistance between harness connector terminals of the X MODE switch.

Scheme 892

CHECK X MODE SYSTEM

Refer to "CVT (TR580)" article for X mode system inspection. < Ref. to CHECK X MODE SYSTEM , INSPECTION, X MODE Switch. >

Scheme 893

1. Disconnect the ground cable from battery.
2. Remove the bulkhead harness connector from TCM.
3. Remove the TCM. NOTE: Replace the TCM and bracket as a set.

Scheme 894

1. Install the TCM to the bracket. CAUTION: To avoid the damage to bracket and TCM, do not remove after installing TCM to bracket. If installed by mistake, the part must be replaced with a new part.
2. Install the TCM. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
3. Install the harness connector to TCM.
4. Connect the battery ground terminal.
5. Perform the operation of AT learning mode. < Ref. to «LEARNING CONTROL»(ref-662155-S04758958322014101300000) . >

SIDE RETAINER

Note. After adjusting the drive pinion backlash and tooth contact, replace the oil seal and O-ring with new parts.

Scheme 895

Scheme 896

Scheme 897

Scheme 898

1. Remove the O-ring.
2. Remove the oil seal.
3. Remove the SPLIT PIN (ST), and then remove the claw. ST 398527700 PULLER ASSY
4. Attach two claws to the outer race, and set the ST to side retainer. ST 398527700 PULLER ASSY
5. Restore the removed claws to original position, and install the pin and split pin.
6. Hold the shaft of ST to avoid removing from side retainer, and then remove the bearing outer race.

ST 398527700 PULLER ASSY

Note. Replace the bearing inner and outer races as a single unit.

Scheme 899

Scheme 900

Scheme 901

Scheme 902

Scheme 903

Scheme 904

Scheme 905

1. Install the washer and differential bevel gear into differential case (LH).
2. Install the differential bevel gear pinions into differential case (LH) and install the pinion shaft.
3. Install the straight pin.
4. Install the differential case (RH) to hypoid driven gear and secure with vise.
5. Install the washer and differential bevel gear to the differential case (RH).
6. Using the ST, install the hypoid driven gear by tightening the installation bolt. ST 18270KA020 SOCKET (E20) Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)
7. While checking the tightening angle with the angle gauge, further tighten the hypoid driven gear mounting bolts. Tightening angle: 28°±2°
8. Measurement of backlash (selection of washer) Install the SUBARU genuine axle shaft to differential case. Part No. 38415AA070 Axle shaft Measure the gear backlash using ST1 and ST2, and then insert the ST2 through the window of differential case. ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE NOTE: Measure the backlash by applying a differential bevel pinion tooth between two differential bevel gear teeth. When measuring, fix the differential bevel pinion in place with a screwdriver covered with cloth, or a similar tool. Specification: 0.13 - 0.18 mm (0.0051 - 0.0071 in) If the backlash is not within specification, select a washer from the table below and replace. Washer Part No. Thickness mm (in) 803038021 0.95 (0.037) 803038022 1.00 (0.039) 803038023 1.05 (0.041)
9. Using the ST, install the left and right taper roller bearings. ST1 499277100 BUSHING 1-2 INSTALLER ST2 398497701 SEAT

Note. After adjusting the backlash and tooth contact, replace the oil seal and O-ring of side retainer with new parts.

Scheme 906

1. Press-fit the bearing outer race to side retainer.
2. Using the ST, install the oil seal. NOTE: Use a new oil seal. Apply differential oil to the oil seal lip. Oil seal has an identification mark (R, L). When installing oil seals, do not confuse the left and right. ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
3. Install the O-ring. NOTE: Use new O-rings. Apply gear oil to O-ring.